Process Control and Automation Network Selection
Simplifying the path for you Standards Certification Education & Training Publishing Conferences & Exhibits
By: Romel Bhullar P.E.
Romel S. Bhullar, P.E. • Romel Bhullar is a Technical Director and Technical Fellow with Fluor Corp. in Aliso Viejo, California. He has over 30 years of experience in process control, process automation and system integration for large refineries, petrochemical, gas processing and LNG plants. He has executed projects from concept to startup for major companies all over the world. He has authored several articles in areas of automation and system integration. He holds post graduate degrees in Chem. E, and MBA. He is licensed professional engineer in state of California.
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Acknowledgment • All trademarks and trade names used belong to the respective entities and organizations. • Some slides are from the websites of the respective organizations and available to public. The links to these sites are available in the references. • Vendor materials are demonstrated for educational purposes only and not endorsed by the author.
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Gas Supply Chain
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Modern LNG Plant Control Philosophy • • • • • •
Totally Integrated Control System Comprised of “Stand Alone Sub-Systems” Best of the Breed Technologies Include Upstream and Downstream Suppliers and Customers Using Single Window of Operations
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Ship Operation related Control System • Ship Operations • Berthing, Stabilization and Marine Monitoring • Ship Board Systems
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Single Control Room • • • • • •
Single Window of Operation Manned by crew for Ship Control Functions LNG Processing and Handling Crew Functions/Duties may be shared No of Operators???? As Needed Process Control Consoles
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Integrated Controls In an Hierarchical Order • • • • • • •
Pyramid type Hierarchy Purdue Model Top layer for Management Information Systems and ERP Business Systems Basic Process and Safety Control Systems Field Devices Ancillary Systems Miscellaneous
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LNG PROCESSING CONTROLS • ONE MAIN CONTROL ROOM • DCS AS HMI FOR THE ENTIRE SYSTEM AND SUBSYSTEMS • SINGLE WINDOW OF OPERATIONS • MAXIMUM USE OF AUTOMATION TECHNOLOGIES No Local Panels/Control • MINIMUM OPERATOR INVOLVEMENT AND OPERATION BY DEFAULT
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MAIN CONTROL ROOM CONSOLE • DCS AS HMI • SINGLE INTEGRATED CONSOLE including CCTV • ERGONOMICALLY DESIGNED TO ISO STANDARDS
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HMI Main Control Console
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MAJOR SYSTEMS AND SUBSYSTEMS • • • • • • • •
DCS EMERGENCY SAFETY SHUTDOWN FIRE AND GAS DETECTION MACHINERY MONITORING INTELLIGENT MOTOR CONTROLS COMPRESSOR CONTROLS CUSTODY METERING LOADING ARMS
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MAJOR CONTROL SUBSYSTEMS • • • • • • • •
IMPORT LOADING ARMS SAAB CUSTODY SYSTEM (Tank Inventory) EXPORT CUSTODY METERING POWER GENERATION LOAD MANAGEMENT Using VSDs PIPE LINE LEAK DETECTION PIPE LINE SCADA CONTD.
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SUBSYSTEMS • • • •
CLOSED CIRCUIT TELEVISION COMMUNICATION SUBSTEMS ODS e.g OSI “PI” AMS OR ASSET MANAGEMENT SYSTEM
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SAFEGUARDING SYSTEMS • ESD TO BE DESIGNED TO ISA 84 OR IEC 65011 LATEST STANDARDS • TUV Germany CERTIFIED • SIL AND HAZOP TO BE IMPLEMENTED IN THE ESD SYSTEMS • DOCUMENTATION • MANAGEMENT OF CHANGE based on Life Cycle • BYPASSES AND PERMISSIVES
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FIRE AND GAS DETECTION • LATEST STANDARDS • NFPA INCLUDING STANDARDS IN REVISION • Any Special Marine LNG carrier requirements??
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ENTERPRISE BASED SYSTEMS • • • •
INFORMATION (IT) FUNCTIONS BUSINESS FUNCTIONS MAINTENANCE AND SUPPORT SYSTEMS Who needs Information and where ON – Shore/Off shore, via Web….etc,
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FIELD DEVICES • • • • • •
FIELD DEVICES (SENSORS AND ACTUATORS) USE DIGITALLY SMART DEVICES NO FIELD BUS USE HART 6.0 OR BETTER USE WIRELESS HART USE WIRELESS FOR MONITORING WHERE PRACTICAL TO MINIMIZE WIRING
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SYSTEM INTEGARTION • USE OPEN INDUSTRY STANDARD PROTOCOLS AND COMMUNICATION MEDIA • USE OPC., ETHERNET WITH TCP/IP • Common systems and devices with ship side where possible
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HMI AND CONSOLES • DCS CONSOLE SINGLE WINDOW TO OPERATIONS AND SAFETY MANAGEMENT • CCTV • ENGINEERING WORKSTATIONS FOR SUBSYSTEMS
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Helpful Strategies on Large Automation Projects 1. Needs Analysis 2. Develop Automation Philosophy and roadmap 3. Define Scope 4. Define Systems and Subsystems 5. Define Field Devices
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Helpful Strategies on Large Automation Projects (Continued) 6. Define Interfaces 7. Define Automation Infrastructure 8. Execution Strategies 9. Monitoring and Control 10.Implementation, Testing and Commissioning
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Automation System Integration Essentials • • • •
Complete understanding of business Operational excellences Organizational structure Organizational boundaries & responsibilities
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Automation System Integration Essentials (Continued) • • • •
Information needs of stakeholders Interview sessions Key dialogues: CEO to operator Translate above to Automation Plan and Control Philosophy, and road map • Evaluate automation assets and enable organization to stay competitive
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System Integration • Start with lowest level field devices and final control elements • Integrate into higher level system • Integrate into overall ( Enterprise Resource Planning) ERP and Automation system • Infrastructure: Security, throughputs, technologies, sharing of resources • Execution strategy: Inside or Outside 25
System Integration Scope: Hardware, Software, Engineering • • • • •
Fiber optic Infrastructure Coax cabling Intrinsic safety or Explosion Proofing Auxiliaries such as: UPS or back-up power Special Requirements: telemetry, radio, wireless etc.
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LNG Safety Automation (Continued) • Use smart sensors to allow for proactive maintenance • Use digital data and calibration, report generation, and logs • Use Open or Proprietary protocols such as Foundation FieldBus (FF) , Profibus analog hardwiring
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LNG Safety Automation (Continued) • Take into account: Reliability, redundancy, back up systems • Automatic validation, partial stroke testing, logging results • System must be digitally integrated
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Availability at what cost?
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Criteria for Sensors and Field Device Integration • Who is interested in the sensor data? • How will you get it to the users? • Make a choice of bus technologies: HART, Foundation FieldBus (FF) Profibus, ModBus, DeviceNet • Wireless • EDDL and Ethernet
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Communication Infrastructure: Define the bandwidth needs • • • • • •
Media interfaces Cabling infrastructure Wireless Security Redundancy Availability
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Define Subsystems • Mechanical Package Interfaces : Loading Arms, Centrifugal Compressors, Marine Monitoring Systems
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Advanced Process Control • Opportunities to Optimize and enhance operations with xx$ barrel of oil • Examples: Compressor stability, Plant Overhead pressure control, Minimize venting, Recondenser level and stability, Inventory monitoring, Resource allocation, Energy management and efficiency
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Maintenance • Proactive maintenance practice is necessary for survival; It not only minimizes downtime but assists with flexibility of operations when required
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Control Room Design & Control Room Location • No reason to locate within or close to process or hazardous area • No need to be in resistant zone • Provide safety, comfort and ergonomics and other Human Factors for peak operator performance during normal operation or emergencies
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From Sensors to Systems What Information Is available • • • • • •
Measured Parameters – Traditional role Current Role is as follows: Sensor Health Information Sensor Operating System and Architecture –by vendor Vendors proprietary Information - shhhh Vendor’s Technology Excellence
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Sensors • Provide Information as follows • Primary variables – what is being sensed • The collected information is packaged to be sent to who needs it • Remember modern digital smart sensors are microprocessor based and have many folders of information for different needs. • Reality is “ANALOG”, the world is not digital.
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Sensor Schematic
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Who is Interested in Sensor Data
CE NA N NTE
EN SO R
VE ND O
OP E RA T IO
M AI
NS
• Process Data for Digital Controls • Data acquisition, OSI PI etc. • Corporation Business needs –ERP, supply chain, Customer • Maintenance • Vendors • Regulatory authorities S
R
AG N A M
EM
T N E
SENSOR 39
What are we really doing • • • • • •
Taking one packet of information from one place to other Sensor to DCS/PLC or digital processors Process data/logic/algorithm/control action DCS to actuator DCS to DCS – implementation in other control strategy DCS to or from other third party subsystems or remote computers
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Choice of field Device Integration • • • • •
Traditional 4-20 mA, analog Advent of digital technology We are going to discuss Inputs sensors and Final control elements – Valves, actuators Primary Measurements like temp. flow, pressure, level are still analog in reality.
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HART SIGNAL
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Media Choice • • • • • •
Serial communication Twisted Pair Coax Cable Fiber Optics Wireless Infrared or Radio
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What are we discussing here • • • • • • • •
We are talking at the bottom layer of the OSI model Bus choices HART Profibus Fieldbus Devicenet Proprietary Ethernet
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OSI Model
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ENTERPRISE INTEGRATION
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Ethernet • • • • •
Brief Overview Open Low cost Gigabytes bandwidth Not limited like others in throughput
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INDUSTRIAL ETHERNET • • • • •
IEEE 802.3 CSMA/CD NON DETERMINISTIC COMMUNICATION MODEL OSI LAYERS LAYERS/STACKS
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Bus Topology
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NETWORK DEVICES • • • • •
INDUSTRIAL CATEGORY ROUTERS MANAGED AND UNMANAGED SWITCHES MANAGED SWITCHS PROVIDE BETTER PERFORMANCE DUE TO MONITORING, REDUNDANCY, SECURITY, BETTER CONTROL AND PROACTIVE MAINTENANCE.
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MANAGED SWITCHES
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CABLING INFRASTRUCTURE • • • • •
COPPER FIBER CONNECTORS POWER - FIELD BUS/ETHERNET INTRINSIC SAFETY/CLASSIFIED
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REMOTE I/O • Can be located within processing area or adjacent to it. • May require special handling depending on environmental requirements (hazardous area). • Can be used in place of field junction boxes. • Reduces “Home-run” wiring costs.
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FOUNDATION FIELDBUS • • • • •
Open, non-priority, star topology. Distance limitations seldom a limiting factor. Communications at 31 kBPS. Typically no more than 15 devices per segment. Number of control valves per segment limited by application.
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TM
Foundation Fieldbus Forward
Intergraph Houston I&E LTUF February 15, 2005 By David Hobart Standards Certification Education & Training Publishing Conferences & Exhibits
What is a Fieldbus? Fieldbus Process Plant P
L
F
Automation and Display Systems
What is a Foundation fieldbus? •Foundation Fieldbus - a digital, two-way multi-drop communication link among intelligent measurement and control devices, and automation and display systems. Fieldbus Network
X
Bus
Terminator
Terminator +
-
Signal Isolation Circuit
Fieldbus Power Supply
Control or Monitoring Device
X
X
Field Devices
Function Blocks
FF FFConfiguration Configuration Software Software
H1 Fieldbus
OUT
AI
IN
OUT
PID
CAS_IN OUT
AO
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fieldbus Communications Function Block
Moves Data from here to there
Function Block
User Layer
You work with data here
User Layer
“Stack”
“Protocol Stacks” accomplish the communications
“Stack”
Physical Layer
You connect wires here
Physical Layer
Wire Medium
Foundation Fieldbus Communications
Fieldbus Device Structure Resource Block – Hardware information
Fieldbus
– Status information
Transducer Block – Isolates function blocks from the hardware – Stores calibration information
Function Blocks – Provide control system behavior
Resource Block
– 10 standard function blocks – 11 Advanced function blocks – ?? Flexible function blocks Physical Sensor or Actuator
Transducer Block
Function Blocks
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Standard Function Blocks •Ten Basic – Part 2 – – – – – – – – – –
Discrete Input Discrete Output Analog Input Analog Output PID/PI/I Controller PD/P Controller Manual loader Bias/Gain Ratio Station Control Selector
•Eleven Advanced – Part 3 – – – – – – – – – – –
Device Control Output Splitter Signal Characterizer Lead/Lag Deadtime Integrator Setpoint Ramp Generator Input Selector Arithmetic Timer Analog Alarm
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Flexible Function Blocks •Any Application in a fieldbus “Wrapper” AI
IN
AI
IN
OUT
AO
OUT_D
DO
OUT_D
DO
Application Algorithm written in
DI
IN_D
DI
IN_D
DI
IN_D
Ladder Logic, C++, Basic or any other language.
Contained Parameters
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HSE Flexible Function Block Characteristics
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• 100% Foundation Fieldbus Solution • Standard FB and IEC 61131-3 Ladder Logic • H1 and HSE macrocycles can be synchronized • FFBs and FBs can execute deterministically within HSE macrocycle • Tight Integration with H1 FBs • Prototype to be included in FBCiHBA demo
HSE HOST
HSE Controller
HSE Controller
FFB
FFB
HSE Control Backbone
Linking Device
Linking Device H1
Linking Device H1
H1
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Integrated Standard PLC Characteristics
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• Hybrid Solution • Includes an integrated standard PLC with all IEC 61131-3 languages • Control strategy can include ladders and standard FF function blocks • Ladders execute asynchronously in PLC but very quickly (< 1 msec) • H1 macrocycle can safely assume nominal ladder execution times • Can be tight Integration with H1 FBs • Available today and included in FBCiHBA demo
Ethernet/IP Control Backbone
HOST
HSE Control Backbone
PLC FF/PLC Exchange Blocks
FF/PLC Exchange Blocks
Linking Device H1
Linking Device
FF/PLC Exchange Blocks
H1
Linking Device H1
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H1 Scheduling
FY FIT
AI-110
110
PID-110 AO-110
110
FIT-110_AI FY-110_PID FY-110_AO
loop 110 period of execution Function Block Execution Cyclic Communication - Publish Acyclic Communication
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4-20ma vs. FF Data Quality DCS
Foundation Fieldbus
TAG = LIC-012 VALUE = 70.62 UNITS = % STATUS = GOOD ALARM = N
15.3 mA
TRANSMITTER
TRANSMITTER
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Expanded View of the Process
Controller
One variable One way
Control Station
Remote I/O Card terminal board
Multivariable Bidirectional
4-20mA analog communication cables Bi-directional communications possible between control valve and transmitters
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HSE Linking Devices And H1 Engineering Workstation
Operator Workstation
Application Packages
H1
Fieldbus Subsystems
L
HSE
COTS Switch/ Firewall
Tw
is te d 10 -p 0 air m e t c ab er s le
Linking Device
FFB
L
HSE Batch Controller
FFB
HSE PLC
Sensor Bus
HSE/H1 Integrated Architecture Engineering Workstation
Operator Workstation
Application Packages
H1
Fieldbus Subsystems
L
HSE
COTS Switch/ Firewall
Tw
is te d 10 -p 0 air m e t c ab er s le
Linking Device
FFB
L
HSE Batch Controller
FFB
HSE PLC
Sensor Bus
BENEFITS OF FFBUS •1. Operating Benefits – Improved Integrity
–Reduced Off Normal Operation –Reduced Down Time
•3. Capital Expense Reduction – Reduced Engineering Costs – Lower Installation Costs – Quicker Start-ups
– Process Control Improvements
–Operate Closer to Limits •2. Maintenance Benefits – Planned Maintenance – Plug and Play Devices – Improved Diagnostic Tools 70
Some Considerations For Fieldbus • Was developed for Layer 1 of the 7 Layer OSI model • Drivers • Does not meet complete needs of a modern refinery, petrochemical or power plant • Limitations on data throughput • Have not kept up with technological evolution – catching up mode • Other technologies are leaping ahead rapidly • Like a middle man, gate keeper role .. seeing work around it already.
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PROFIBUS DP • Open, non-priority, linear topology. • Fastest and most widely implemented bus • Communication speed inversely proportional to bus length (1.2 mBPS typical) • 120 drops maximum
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PROFIBUS PA • • • •
Open, non-priority, linear topology. May operate on a Profibus DA segment Communications at 31 kBPS 10-20 drops depending on area classification
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DEVICENET • Open, non-priority, star topology. • Communication speed inversely proportional to bus length (100-500 kBPS typical) • Used typically for discrete devices such as starters, VFDs, relays, valve positions, etc. • 60 drops maximum
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Wireless • Proprietary communications protocol between sender and receiver. • Usually requires “line of sight” between devices
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Modbus • Brief overview • In US , it is industry workhorse. • There are others like Device net , Arcnet, cheapnet and so on.
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MODBUS IMPLEMENTATION
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Standards Certification Education & Training Publishing Conferences & Exhibits
DELTA V MODBUS TCP COMMUNICATION
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MODBUS IMPLEMENTATION
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TCP/IP IE PROTOCOLS
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IE PROTOCOL COMPARISON
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Introduction • Choice of field Device Integration • I/O or system data integration
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Need for Integration Into the Digital Control System • Digital Systems • Data needs - Information needs are immense • Information hungry world
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What an Integrator needs to do • Old Plants modernization • New Plants • Let’s look at needs of a new grass root LNG facility automation.
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What are the available solutions • There is no such thing as - “Perfect Tool” • ONE SHOE FITS ALL – Does not work • NO ONE BUS COVERS ALL THE NEEDS OF A MODERN PROCESS PLANT & Never will. • Large, complex I/O based systems are difficult. • In this information world “We need additional information to understand and process more information”
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HIERACHICAL CONTROLS
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What do I need to consider besides wiring costs • • • • •
Life Cycle Cost Technology Cost Technology life span before obsolescence Organizations road map Engineering, construction, commissioning and maintenance • “Field bus was developed to replace wiring and promote inter-operability”
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BUS SELECTION CONSIDERATIONS • • • • • • • •
Bandwidth Area Classification Field Devices Control Strategy Distance, I/O Density Multiple Bus Requirements Installation Costs Region or Location of Plant/Project
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BUS IMPLEMENTATION • • • • • • •
Field Instrument Segregation Number of Devices Per Bus Control Strategy Bus Hardware Requirements Capital Cost Operating and Maintenance Data Security
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Fieldbus and Remote I/O comparisons • • • • • •
From FuRIOS 2 Study based upon a small pharmacy plant Sponsored by P&F Slight 3 to 5% cost advantage in wiring cost Other factors were ignored. P&F only supplier of Safety Barriers.
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DESIGN CONSIDERATIONS • • • • •
Density of Devices Segment Segregation Operational Requirements Impact of Loss of Data Control Functions
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Complications • • • • • • • • •
I/O mix I/O quantity Operating Systems Communication media and protocols Old Plant New Plant Technical issues Site location –Arctic, Saudi Desert, Rain forest Remote
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PLANT SAFETY SYSTEM • IPSS IS A CRITICAL COMPONENT FOR ANY LNG PLANT • COMPLIED WITH ALL THE EXISTING STANDARDS, BEST INDUSTRIAL PRACTICES, AND REGULATORY AGENCY REQUIREMENTS • USED BEST OF THE BREED AVAILABLE TECHNOLOGY.
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PLANT SAFETY SYSTEMS • • • • • •
MOST CRITICAL COMPONENT EXTREMELY HIGH AVAILABILITY EXTREMELY HIGH RELIABLITY TESTING/CERTIFICATION AUDITING TRAIL REGULATORY REQUIREMENTS
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SAFETY STANDARDS FOR PROCESS INDUSTRIES • ISA S-84 1996 HARD WIRES ONLY. • ISA S84.00.01 ALSO IEC 61511-2003, ALLOWS A DIGITAL BUS COMMUNICATION. • ISA SP84 WG 1 ON SUPPORT FOR FIELDBUS.
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OBJECTIVES OF ISA S 84 WG1 ARE • CERTIFIED SIL LEVEL OF SIS • INTEROPERABILITY - NON PROPRIETARY • COEXISTANCE OF SAFETY AND NON SAFETY RELATED DEVICES ON THE BUS • DIAGNOSITIC REQUIREMENTS • FAULT TOLERANCE • SECURITY • HOT REPLACEMENT • TESTING • FAST RESPONSE
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SAFETY FIELDBUS (W2) • TECHNOLOGY EXISTS TODAY • STANDARDS ? – DRAFT MAY BE ACCEPTED BY NOW. • PARTIAL STROKE TESTING CAPABILITIES ARE THERE. • HAVE SIMILAR BENEFITS AS CLAIMED BY FIELDBUS
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Implementation of complete system integration requires • • • • •
Technologies Engineering Project Execution Client/Project specific requirements Regulatory agencies
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Technology factors • • • • • • • •
Safety Availability Reliability System Integration Application Software Subsystem Integration Proprietary Technologies Special requirements
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Engineering and Execution • • • •
Work Processes Internal Interfaces External Interfaces Vendor Information exchange
• • • • •
Organization Life Cycle Cost Cost Structure Pre-Investment Guarantees/ Warrantees
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Emerging Technologies • • • • • • • •
Lot of functional duplication – paying twice Watch out for EDDL Capabilities of Ethernet OPC model Traditional role of transmitter is disappearing From sensor to system – bus or no bus Wireless (Windows CE, Palm OS, Apple I-Pod) Security
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EDDL Electronic Device Description Language Each field device has one
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OPC OVERVIEW
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DO NOT TRUST YOUR DATA TO STROKE OF LUCK
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INDUSTRIAL NETWORK SECURITY • THREATS TO YOUR NETWORK • BUILDING EFFECTIVE NETWORK SECURITY ON YOUR INDUSTRIAL NETWORK
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SECUIRTY THREATS • • • •
MALWARE HACKERS NETWORK OVERLOAD PHYSICAL THREATS
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BUILDING EFFECTIVE DEFENCE • • • • • • • •
HAVE A PLAN EDUCATION COMPANY ACCESS POLICIES SECURITY SOFTWARE ROUTERS FIREWALLS DEMILITARIZED ZONES BACKUP AND RECOVERY
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DEMILITARIZED ZONE -
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Juniper Networks Solution.
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Introduction • Choice of field Device Integration • I/O or system data integration
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Conclusion • Understand the business supply chain • Understand your business Organization hierarchies and data requirements • Have an all inclusive Automation road map • Define your systems, sub-systems and interfaces • Consider using the “best of a breed” technologies for Networks, Field buses, • Deliver what is needed for current and future needs • Use COTS components, connectors, cables, switches, servers, HMIs etc.
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Contact Information & Useful Websites • • • • • • •
www.hartcom.org www.fieldbus.org www.profbus.com www.opcfoundation.org www.eddl.org www.odva.org www.modbus.org
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E-mail
[email protected] Telephone 949-349-6762
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OPC Fundamentals, Implementation and Application by Fran Iwanitz and Jurgen Lange, Huthig Verlag Heidelberg The Industrial Ethernet Networking Guide by Sterling & Wissler, Thomson Publishing Automation Network Selection BY Dick Caro, ISA Publication
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[email protected] [email protected] [email protected] [email protected]
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